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Article(id=1321511460434465379, tenantId=1146029695717560320, journalId=1220038251117760515, issueId=1321508707721138247, articleNumber=null, orderNo=null, doi=10.11868/j.issn.1001-4381.2024.000056, pmid=null, cstr=32421.14.j.issn.1001-4381.2024.000056, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1705939200000, receivedDateStr=2024-01-23, revisedDate=null, revisedDateStr=null, acceptedDate=1708617600000, acceptedDateStr=2024-02-23, onlineDate=1793002484663, onlineDateStr=2026-10-26, pubDate=1766160000000, pubDateStr=2025-12-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1793002484663, onlineIssueDateStr=2026-10-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1793002484663, creator=13701087609, updateTime=1793002484663, updator=13701087609, issue=Issue{id=1321508707721138247, tenantId=1146029695717560320, journalId=1220038251117760515, year='2025', volume='53', issue='12', pageStart='1', pageEnd='296', issueExtLink='null', onlineDate='null', pubDate='1766160000000', pubDateStr='2025-12-20', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1793001828365, creator='13701087609', updateTime=1793001828365, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext=null, issueFiles=null, downloadFileDto=null}, startPage=230, endPage=238, ext={EN=ArticleExt(id=1321511460631597668, articleId=1321511460434465379, tenantId=1146029695717560320, journalId=1220038251117760515, language=EN, title=Microstructure and mechanical properties of 7050-T7451 high-strength aluminum alloy joints by laser-arc hybrid welding, columnId=1220689384450478826, journalTitle=Journal of Materials Engineering, columnName=RESEARCH ARTICLE, runingTitle=null, highlight=null, articleAbstract=

To promote the further application of high-strength aluminum alloys in the aviation field，the 7050-T7451 aluminum alloy with 4 mm thickness is carried out by laser-melt inert-gas（MIG）hybrid welding. The results show that a well-formed weld seam can be obtained with reasonable matching of welding parameters，while welding at higher speeds is easy to produce cracks. When the welding speed is controlled at 0.9 m/min or below，and the weld back-width ratio is controlled above 0.4，the cracks and porosity defects can be effectively suppressed. The weld zone is mainly composed of equiaxed grain structures with significant differences in size. Near the fusion zone，there is a fine-grained layer approximately 20-50 μm wide，and only a minimal amount of columnar grains forms adjacent to this fine-grained layer. No phase transformation or recrystallization occurs in the heat-affected zone. The as-welded joint achieves an average tensile strength of approximately 377 MPa， equivalent to about 73% of the base metal strength， significantly outperforming the tensile properties of laser self-fusion welded joints.

, authors=Fei XU1, Wenqiang GAO1, Bin LIU2, Pengcheng LEI2, authorsList=Fei XU, Wenqiang GAO, Bin LIU, Pengcheng LEI, authorCompany=null, correspAuthors=Fei XU, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1321511462909104767, articleId=1321511460434465379, tenantId=1146029695717560320, journalId=1220038251117760515, language=CN, title=7050-T7451高强铝合金激光电弧复合焊接接头组织与力学性能, columnId=1220689384622445292, journalTitle=材料工程, columnName=研究论文, runingTitle=null, highlight=null, articleAbstract=

为促进高强铝合金在航空领域的进一步推广应用，开展4 mm厚7050-T7451铝合金激光-熔化极惰性气体保护复合焊接研究。结果表明：焊接参数合理匹配能够获得成形饱满的焊缝，而较高焊接速度施焊极易产生焊接裂纹，只有当焊接速度控制在0.9 m/min及以下、焊缝背宽比控制在0.4以上，才能有效抑制裂纹和气孔缺陷；焊缝区主要为尺寸差异较大的等轴晶组织，在熔合区附近存在宽度约为20~50 μm的细晶层组织，仅在靠近细晶层的局部，生成极少量的柱状晶组织；热影响区未发生相变和再结晶；焊态接头平均抗拉强度约为377 MPa，达到母材的73%，远高于激光自熔焊接接头的拉伸性能。

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许飞（1982—），男，高级工程师，硕士，研究方向为轻质合金激光及激光电弧复合焊接，联系地址：北京市朝阳区朝阳路1号中国航空制造技术研究院（100024），E-mail：
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Materials Science and Engineering： A， 2003， 351（1/2）： 304-309., articleTitle=A mechanism for the formation of equiaxed grains in welds of aluminum-lithium alloy 2090, refAbstract=null), Reference(id=1321926870292091189, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, doi=null, pmid=null, pmcid=null, year=2017, volume=38, issue=8, pageStart=119, pageEnd=123, url=null, language=null, rfNumber=[24], rfOrder=40, authorNames=许飞, 陈俐, 芦伟, journalName=焊接学报, refType=null, unstructuredReference=许飞， 陈俐， 芦伟， 等. 热输入对6A02铝合金光纤激光焊缝成形的影响［J］. 焊接学报， 2017， 38（8）： 119-123., articleTitle=热输入对6A02铝合金光纤激光焊缝成形的影响, refAbstract=null), Reference(id=1321926870363394358, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, doi=null, pmid=null, pmcid=null, year=2017, volume=38, issue=8, pageStart=119, pageEnd=123, url=null, language=null, rfNumber=[24], rfOrder=41, authorNames=XU F, CHEN L, LU W, journalName=Transactions of the China Welding Institution, refType=null, unstructuredReference=XU F， CHEN L， LU W， et al. 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Materials Science and Engineering： A， 2019， 768： 138478., articleTitle=Microstructure and mechanical properties of a novel Sc and Zr modified 7075 aluminum alloy prepared by selective laser melting, refAbstract=null), Reference(id=1321926870698938681, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, doi=null, pmid=null, pmcid=null, year=2023, volume=68, issue=null, pageStart=103526, pageEnd=null, url=null, language=null, rfNumber=[27], rfOrder=44, authorNames=LIU D H, WU D J, GE C R, journalName=Additive Manufacturing, refType=null, unstructuredReference=LIU D H， WU D J， GE C R， et al. Superior strength of laser-arc hybrid additive manufactured Al-Zn-Mg-Cu alloy enabled by a tunable microstructure［J］. 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label=Fig.7, caption=Keyhole type porosity defect, figureFileSmall=/TOLDWN5GVyxlA7dIqbnpw==, figureFileBig=X7+QM2Bl4RUdDS0KEGsh7w==, tableContent=null), ArticleFig(id=1321926861505024247, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=图7, caption=小孔型气孔缺陷, figureFileSmall=/TOLDWN5GVyxlA7dIqbnpw==, figureFileBig=X7+QM2Bl4RUdDS0KEGsh7w==, tableContent=null), ArticleFig(id=1321926861572133112, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Fig.8, caption=Structures of 7050-T7451 aluminum alloy joints by laser-arc hybrid welding（a）cross-section macroscopic morphology；（b）microstructure of A zone in Fig.（a）；（c）microstructure of B zone in Fig.（a）, figureFileSmall=7Sh0WjUwrVQR2g3mnQTKhw==, figureFileBig=LG3gTguDKx6zFkFciBrNrg==, tableContent=null), ArticleFig(id=1321926861656019193, tenantId=1146029695717560320, journalId=1220038251117760515, 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journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Fig.10, caption=Distribution of microhardness of joints in transverse direction, figureFileSmall=WPlEcFOmefeRwmHR70SDdA==, figureFileBig=KcfXO8cHZ06zkxB2WpoELA==, tableContent=null), ArticleFig(id=1321926861970591997, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=图10, caption=焊接接头横截面的横向显微硬度分布, figureFileSmall=WPlEcFOmefeRwmHR70SDdA==, figureFileBig=KcfXO8cHZ06zkxB2WpoELA==, tableContent=null), ArticleFig(id=1321926862046089470, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Fig.11, caption=Stress-strain curves of baser metal（a） and welded joints（b）, figureFileSmall=/BRshX/VfWkRQQmjF+FPRg==, figureFileBig=ujY5urMwSsGY3OEeHno6Hw==, tableContent=null), ArticleFig(id=1321926862129975551, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, 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label=Fig.13, caption=SEM morphologies of fracture surface, figureFileSmall=B9SvHTnWVXu2obh+CSSybw==, figureFileBig=UwcqkTKutROYM3Zw60SL8A==, tableContent=null), ArticleFig(id=1321926862436159747, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=图13, caption=断口SEM形貌, figureFileSmall=B9SvHTnWVXu2obh+CSSybw==, figureFileBig=UwcqkTKutROYM3Zw60SL8A==, tableContent=null), ArticleFig(id=1321926862515851524, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Table 1, caption=

Chemical compositions of 7050-T7451 aluminum alloy and filler wire （mass fraction/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
MaterialSiFeCuMnMgCrZnTiZrAl
7050-T7451≤0.12≤0.152.0-2.6≤0.101.9-2.6≤0.045.7-6.7≤0.060.08-0.15Bal.
ER53560.250.400.100.05-0.204.5-5.50.05-0.200.250.15Bal.
), ArticleFig(id=1321926862578766085, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=表1, caption=

7050-T7451铝合金及填充焊丝的化学成分（质量分数/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
MaterialSiFeCuMnMgCrZnTiZrAl
7050-T7451≤0.12≤0.152.0-2.6≤0.101.9-2.6≤0.045.7-6.7≤0.060.08-0.15Bal.
ER53560.250.400.100.05-0.204.5-5.50.05-0.200.250.15Bal.
), ArticleFig(id=1321926862650069254, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Table 2, caption=

Tensile properties of base metal and filler wire

, figureFileSmall=null, figureFileBig=null, tableContent=
Material

Tensile strength/

MPa

Yield strength/

MPa

Ultimate elongation/%
7050-T7451517441.57.25
ER535626815220.5
), ArticleFig(id=1321926862725566727, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=表2, caption=

母材和焊丝的拉伸性能

, figureFileSmall=null, figureFileBig=null, tableContent=
Material

Tensile strength/

MPa

Yield strength/

MPa

Ultimate elongation/%
7050-T7451517441.57.25
ER535626815220.5
), ArticleFig(id=1321926862826230024, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Table 3, caption=

Main welding parameters of laser-arc hybrid welding

, figureFileSmall=null, figureFileBig=null, tableContent=
Welding speed/（m·min-1）Laser power/kWWelding current/A
0.9-3.02.0-4.550-100
), ArticleFig(id=1321926862901727497, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=表3, caption=

激光电弧复合焊接主要焊接参数

, figureFileSmall=null, figureFileBig=null, tableContent=
Welding speed/（m·min-1）Laser power/kWWelding current/A
0.9-3.02.0-4.550-100
), ArticleFig(id=1321926862981419274, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=EN, label=Table 4, caption=

Tensile test results of welded joints

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Material stateSample numberTensile strength/MPaYield strength/MPaUltimate elongation/%Fracture position
Joint by laser-arc hybrid weldingH13593081.5Near the fusion zone
H23793012.0Near the fusion zone
H33942952.5Near the fusion zone
Average3773012.0
Joint by laser welding［12］3071.08Welding zone
), ArticleFig(id=1321926863065305355, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321511460434465379, language=CN, label=表4, caption=

焊接接头的拉伸测试结果

, figureFileSmall=null, figureFileBig=null, tableContent=
Material stateSample numberTensile strength/MPaYield strength/MPaUltimate elongation/%Fracture position
Joint by laser-arc hybrid weldingH13593081.5Near the fusion zone
H23793012.0Near the fusion zone
H33942952.5Near the fusion zone
Average3773012.0
Joint by laser welding［12］3071.08Welding zone
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7050-T7451高强铝合金激光电弧复合焊接接头组织与力学性能
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许飞 1 , 高文强 1 , 刘斌 2 , 雷鹏程 2
材料工程 | 研究论文 2025,53(12): 230-238
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材料工程 |研究论文 2025 , 53 (12) : 230 -238
7050-T7451高强铝合金激光电弧复合焊接接头组织与力学性能
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许飞1 , 高文强1, 刘斌2, 雷鹏程2
作者信息
  • 1.中国航空制造技术研究院，北京 100024
  • 2.航空工业庆安集团有限公司，西安 710077
通讯作者:
许飞（1982—），男，高级工程师，硕士，研究方向为轻质合金激光及激光电弧复合焊接，联系地址：北京市朝阳区朝阳路1号中国航空制造技术研究院（100024），E-mail：
Microstructure and mechanical properties of 7050-T7451 high-strength aluminum alloy joints by laser-arc hybrid welding
Fei XU1 , Wenqiang GAO1, Bin LIU2, Pengcheng LEI2
Affiliations
  • 1.AVIC Manufacturing Technology Institute，Beijing 100024，China
  • 2.AVIC Qing’an Group Co. ，Ltd. ，Xi’an 710077，China
出版时间: 2025-12-20 doi: 10.11868/j.issn.1001-4381.2024.000056
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摘要
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为促进高强铝合金在航空领域的进一步推广应用，开展4 mm厚7050-T7451铝合金激光-熔化极惰性气体保护复合焊接研究。结果表明：焊接参数合理匹配能够获得成形饱满的焊缝，而较高焊接速度施焊极易产生焊接裂纹，只有当焊接速度控制在0.9 m/min及以下、焊缝背宽比控制在0.4以上，才能有效抑制裂纹和气孔缺陷；焊缝区主要为尺寸差异较大的等轴晶组织，在熔合区附近存在宽度约为20~50 μm的细晶层组织，仅在靠近细晶层的局部，生成极少量的柱状晶组织；热影响区未发生相变和再结晶；焊态接头平均抗拉强度约为377 MPa，达到母材的73%，远高于激光自熔焊接接头的拉伸性能。

7050-T7451铝合金  /  激光电弧复合焊接  /  焊缝成形  /  背宽比  /  组织  /  拉伸性能

To promote the further application of high-strength aluminum alloys in the aviation field，the 7050-T7451 aluminum alloy with 4 mm thickness is carried out by laser-melt inert-gas（MIG）hybrid welding. The results show that a well-formed weld seam can be obtained with reasonable matching of welding parameters，while welding at higher speeds is easy to produce cracks. When the welding speed is controlled at 0.9 m/min or below，and the weld back-width ratio is controlled above 0.4，the cracks and porosity defects can be effectively suppressed. The weld zone is mainly composed of equiaxed grain structures with significant differences in size. Near the fusion zone，there is a fine-grained layer approximately 20-50 μm wide，and only a minimal amount of columnar grains forms adjacent to this fine-grained layer. No phase transformation or recrystallization occurs in the heat-affected zone. The as-welded joint achieves an average tensile strength of approximately 377 MPa， equivalent to about 73% of the base metal strength， significantly outperforming the tensile properties of laser self-fusion welded joints.

7050-T7451 aluminum alloy  /  laser-arc hybrid welding  /  weld formation  /  back-width ratio  /  microstructure  /  tensile property
许飞, 高文强, 刘斌, 雷鹏程. 7050-T7451高强铝合金激光电弧复合焊接接头组织与力学性能. 材料工程, 2025 , 53 (12) : 230 -238 . DOI: 10.11868/j.issn.1001-4381.2024.000056
Fei XU, Wenqiang GAO, Bin LIU, Pengcheng LEI. Microstructure and mechanical properties of 7050-T7451 high-strength aluminum alloy joints by laser-arc hybrid welding[J]. Journal of Materials Engineering, 2025 , 53 (12) : 230 -238 . DOI: 10.11868/j.issn.1001-4381.2024.000056
正文
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7050铝合金是Al-Zn-Mg-Cu系可热处理强化的高强度变形铝合金，兼具优良的韧性、高疲劳强度和抗应力腐蚀性能，综合性能优异［1］，因此，被广泛用于制造飞机上的主承力结构件，包括机身框、隔板、机翼壁板、翼梁与翼肋等。然而，该材料普遍以机械加工或铆接结构为主，仅在一些少量的非承力部位采用氩弧焊接方法实现薄壁结构的冶金连接。而氩弧焊接变形大、易产生裂纹且接头力学性能较低，严重制约了合金的工程应用拓展。
激光电弧复合焊接以激光热源为主，基于“小孔效应”原理［2-3］，既能保持激光焊接热输入低、焊接变形小、接头质量高等优点，又能显著改善焊缝成形［4］，克服激光焊接装配精度高［5］和电弧焊接效率低［6］等局限性，是薄壁复杂曲面结构的理想焊接方法。目前，7×××系铝合金焊接方面的研究报道较多［7-8］，而关于激光及激光复合焊接方面的研究报道则相对较少。侯艳喜等［9］研究了6 mm厚A7N01铝合金的激光-熔化极惰性气体保护（melt inert-gas，MIG）复合焊接，焊缝成形良好，且焊接接头平均抗拉强度为271 MPa，达到母材（base material，BM）的60%。Zhang等［10］开展了2 mm厚7075-T6铝合金激光-MIG复合焊接接头的疲劳测试，表明复合焊接能够提高接头疲劳性能，且疲劳裂纹萌生于气孔部位。张林［11］采用激光-MIG复合穿孔焊+MIG盖面焊的方法，实现了20 mm厚7A52铝合金的高效焊接。在7050铝合金焊接方面，谢超杰等［12］开展了3 mm厚7050铝合金光纤激光焊接研究，受焊缝表面塌陷影响，焊接接头抗拉强度仅达到307 MPa。吴圣川等［13］开展了高焊接速度6 m/min条件下的2 mm厚7050-T7451铝合金激光电弧复合焊接组织及缺陷容限评价，然而，在较低的焊接速度或焊接更厚材料方面的相关研究报道则十分匮乏。
对于小型复杂焊接结构，为保证良好的焊接过程稳定性和质量一致性，焊接速度不宜过快，而应控制在合理范围内。基于激光电弧复合热源几何位置设计（光弧间距、焊枪倾斜角度等）以及焊接方向、焊接惰性气体保护等与焊缝成形相关性的优化实验结果，本工作开展了4 mm厚7050铝合金光纤激光-MIG电弧旁轴复合焊接，分析焊缝成形及缺陷控制，观察焊接接头微观组织形貌，并对其显微硬度和拉伸性能进行了测试。
1 实验材料与方法
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实验采用7050-T7451高强铝合金和直径Φ1.2 mm的ER5356焊丝，其化学成分和拉伸性能分别如表1和表2所示。母材经铣削加工成焊接试板，尺寸为200 mm×100 mm×4.0 mm，焊前按照HB/Z 20018—2012规定的化学清洗方法去除母材表面的油污和氧化膜。
焊接系统以额定功率5 kW的光纤激光器和推-拉丝式铝焊专机为核心，由六轴联动机械手通过专用焊炬带动激光电弧复合焊枪实现动光式焊接（图1）。激光采用零离焦，焦距255 mm，焦斑直径Φ0.525 mm。铝焊专机为一体化智能焊机，当焊接电流调整或变化时，电弧电压、送丝速度等其他焊接参数会自动匹配优化。为简化实验过程，实验参数调整仅选取焊接速度、激光功率、焊接电流3个主要焊接参数，其他参数（如保护气体成分、保护气体气流速率、电弧弧长、激光和电弧两热源的相对几何位置等）均采用前期的工艺优化结果，主要焊接参数的调节范围详见表3。实验采用对接拼焊方式，焊件不需要开设坡口。焊接过程中通入正反面惰性保护气体，对焊接熔池和焊缝高温区进行全方位保护。
焊接后采用X射线检测法对焊接接头的内部质量进行无损检测，在焊缝成形良好的基础上，截取横向金相试样和拉伸试样（图2）。金相试样使用Keller试剂腐蚀后，采用Olympus GX53倒置金相显微镜、SUPRA55 Sapphire场发射扫描电镜和Symmtry S2 EBSD系统观察与分析焊接接头的微观组织；采用OXFORD instruments X-maxN能谱仪测量焊缝区的化学成分；显微硬度测试采用QATM Qness 60维氏硬度仪，间隔为200 µm，实验力为0.98 N，加载时间为15 s；室温拉伸性能测试采用5982电子万能材料试验机，按照GB/T 2651—2023开展焊接接头的拉伸性能测试。
2 结果与分析
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2.1 7050-T7451铝合金激光电弧复合焊接成形及缺陷分析
当采用高焊接速度和匹配的激光功率实施深熔穿透焊接时，焊接电流应控制在一定范围内才能获得成形饱满的焊缝。以焊接速度3 m/min和激光功率4.5 kW为例（图3），当焊接电流小于50 A时，受焊接速度过快和电弧易产生飘移的影响，焊缝呈现出断续状和严重凹陷特征；当焊接电流为50~90 A时，由于焊丝向熔池中补充的液体填充量不足以弥补自熔激光焊产生的表面凹陷/下塌缺陷，故焊缝正面易出现不同程度的凹陷，且焊接电流越小，凹陷量越大。任取50 mm长度的焊缝，其中心余高情况如图4所示。当焊接电流为100 A时，焊缝正面出现适量余高，范围为0.05~0.2 mm，焊缝饱满美观。
从焊接接头内部质量可以发现，当焊接速度为3 m/min、激光功率为4.5 kW时所获得的焊缝内部均有不同程度的横向裂纹，且焊接裂纹的数量和长度随焊接电流的增大而增加。这与高焊接速度条件下的母材快速熔凝过程密切相关，即焊接速度较快，导致焊接过程中的熔池体积小（对应的焊缝正反面熔宽较窄），而且熔池的冷却速度快，即熔池结晶的温度梯度大、焊缝金属的拘束应力大，在焊缝金属的拘束应力和母材的共同作用下，裂纹易从熔合区和热影响区产生，严重时会贯穿整条焊缝。
为缓解焊缝金属的拘束应力，降低熔池结晶的温度梯度并消除焊接裂纹，焊接速度不宜过快。当焊接速度降至1.2 m/min，焊接电流为50 A，激光功率在2.6~3.0 kW范围内，在焊缝起焊和收焊部位仍然存在零星的微裂纹。当焊接速度降至0.9 m/min，焊接电流保持50 A，激光功率在2.4~2.8 kW范围内，焊缝正反面成形和内部质量均良好（图5）。当激光功率由2.8 kW逐渐降低至2.4 kW时，焊缝正面熔宽基本保持不变，而背面熔宽持续减小（图6），即焊缝背宽比［14］（焊缝背面熔宽与正面熔宽之比）逐渐降低。在激光电弧复合穿透焊接过程中，激光和电弧两热源产生能量耦合，电弧等离子体能够稀释小孔上出口附近的光致等离子体，使激光保持强穿透性，故激光功率对焊缝背面成形或背面焊缝熔宽的影响较大；激光产生的光致等离子体也增加了电弧的稳定性，电弧主要作用于焊缝正面［15-16］且电弧焊缝熔宽往往远大于激光焊缝熔宽，故电弧焊对焊缝正面成形或焊缝正面熔宽的影响较大。当激光功率进一步降低时，焊缝背宽比降低至0.4以下，极易出现焊缝局部熔透不足并伴随着较大尺寸小孔型气孔缺陷［17-19］，如图7所示。此外，当焊接速度继续降低，在相匹配的激光功率作用下，激光焊接热输入更大，复合热源易产生更大的焊接应力和变形，并引发接头显微组织粗化等问题。
2.2 7050-T7451铝合金激光电弧复合焊接组织分析
实验选取最佳焊缝成形的优化焊接参数：焊接速度0.9 m/min，焊接电流50 A和激光功率2.8 kW。该焊接条件下，7050-T7451铝合金激光电弧复合焊接接头横截面宏观形貌（图8（a））显示，焊缝区（welding zone，WZ）呈现为上宽下窄的近X形，正反面均有一定的余高，焊缝背宽比约为0.72。这主要归因于焊接过程中能量分布的不均匀性。焊接过程中，焊接小孔贯穿母材壁厚，在高能量密度激光作用下，小孔分别向上、向下喷发金属蒸气/等离子体，焊接小孔和动态聚集于小孔上、下出口处的高温金属蒸气/等离子体以及在小孔上出口吸引的MIG电弧等离子体，组成了近似于“两点一线”热源［20］，且上点热源能量大于下点热源，故焊缝正面熔宽大于背面熔宽。热影响区（heat-affected zone，HAZ）宽度约2.2~3.5 mm，与母材区相比，HAZ未发生相变和再结晶，仅呈现出一定程度的颜色暗化现象。而母材区为典型的轧制组织，晶粒存在一定的轧制取向。
在熔合区附近形成宽度约为20~50 μm的晶粒尺寸非常细小的细晶层，其晶粒度明显小于其他焊缝区和母材区，如图8（b）所示。7050铝合金中含有一定量的Zr和Ti，可与Al形成高熔点化合物Al3Ti、Al3Zr和Al3（Ti，Zr），其不仅符合“界面共格对应原则”，在固液界面减小液固相界面张力，降低金属异质形核的临界形核功，而且为熔池中的异质形核提供所需的界面，导致大量晶核产生。根据熔池温度场分布，熔池边缘温度略高于母材熔点，存在一层运动速度很低的附面层［21］。在该附面层中，大量难熔质点聚集，造成该区域的形核率和形核速度均极高，即产生了数量多且尺寸细小的细晶层组织。有研究表明，细晶层组织可能与接头的宏观失效行为密切相关［22-23］。
高能量密度的光纤激光和MIG电弧作用于同一熔池，液态熔池不仅承受自身重力、表面张力、小孔动态波动引起的熔池震荡作用，还承受电弧的弧柱和磁吹力、熔滴落入熔池的作用力以及惰性保护气吹力等，故焊接过程是一个极其复杂的传热传质过程。在上述作用力的综合作用下，熔池快速凝固形成焊缝。从图8（c）可以看出，焊缝区以尺寸差异较大的等轴晶为主，仅在靠近细晶层的局部，存在极少量的柱状晶组织。7050铝合金母材富含大量溶质元素，高熔点化合物Al3Ti、Al3Zr和Al3（Ti，Zr）提供大量现成的晶核，在熔池α-Al结晶并长大的同时，大量溶质元素富集导致成分过冷度逐渐增加，随着熔池的冷却，最先结晶的晶粒和随后结晶的晶粒，呈现出不同的晶粒特征，即最先结晶的晶粒呈现为等轴树枝晶组织，且二次枝晶比较发达；而随后结晶的晶粒则呈现为等轴胞状晶组织。
由焊缝区EDS检测结果（图9）分析可知，受焊接熔池中Mg、Zn元素蒸发烧损的影响，焊缝区Mg、Zn元素含量均出现一定程度的降低。同时，焊缝区晶界存在Cu元素的偏聚，而其他合金元素（Zn、Mg）在晶界或界内，分布比较均匀。
2.3 7050-T7451铝合金激光电弧复合焊接接头硬度分布
7050-T7451铝合金激光电弧复合焊接接头（焊态）横截面的硬度分布如图10所示。可以看出，焊缝区显微硬度平均值为92.8HV，仅达到母材区平均硬度（167.8HV）的55.3%，这与焊接熔凝过程中强化相溶解于熔池而并未在凝固过程中充分析出以及焊接过程中ER5356填充焊丝与母材低强匹配有关。热影响区显微硬度平均值为161.9HV，达到母材区的96.5%，这与前述分析的该区未发生固态相变的微观组织相吻合。由于热影响区与焊缝区之间存在较大的硬度突变及其微观组织差异较大，导致该部位很可能成为力学性能的薄弱环节。为缓解或改善该部位性能较低的问题，可以适当降低焊接热输入［24-25］、焊丝中增加微量强化元素［26］或焊后采用固溶+时效热处理方法［27］进行接头强化。
2.4 7050-T7451铝合金激光电弧复合焊接拉伸性能分析
4.0 mm厚7050-T7451铝合金激光电弧复合焊接接头（焊态）的拉伸性能结果如表4和图11所示。可以看出，焊态接头平均抗拉强度约为377 MPa，约为母材的73%；平均断后伸长率为2.0%，仅达到母材的28%。由此表明，激光电弧复合焊接接头经历快速熔凝后，虽然产生了一定的接头软化现象，然而，其抗拉强度仍然保持在较高水平，比激光自熔焊接接头高22.8%［12］。与激光自熔焊相比，激光电弧复合焊接成形饱满，能够克服其表面的下塌、咬边等成形不良缺陷，减小焊接接头的应力集中；同时，填充焊丝能够弥补部分Mg强化元素的蒸发烧损，故激光电弧复合焊接接头的拉伸性能优于激光自熔焊。
从拉伸断口宏观形貌（图12）可以看出，焊态接头全部断裂于熔合区附近，断裂面比较平整且与焊缝表面基本呈垂直状态，断裂处未产生明显的缩颈现象。图13为断口SEM形貌。可以发现，拉伸断口呈现以脆性断裂为主的混合断裂特征，其断裂模式以沿晶断裂为主，也存在数量较多的韧窝，韧窝较浅，在韧窝内部，残留有少量的第二相粒子，这也是焊接接头保持较高强度的主要原因。同时，断口处晶粒的形态为细小的等轴晶组织，结合断裂宏观位置和微观组织形貌，可以推测断裂发生在熔合区附近的细晶层部位，这与该部位的抗变形能力较弱密切相关。
3 结论
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（1）焊接电流应与焊接速度、激光功率等相匹配，才能获得成形饱满的焊缝。为缓解4 mm厚7050-T7451铝合金激光电弧复合焊接的拘束应力，降低熔池结晶的温度梯度并消除焊接裂纹，焊接速度宜控制在0.9 m/min及以下。焊缝背宽比应控制在0.4以上，才能有效抑制气孔缺陷。
（2）焊接接头热影响区未发生相变和再结晶，仅呈现出一定程度的颜色暗化现象；焊缝区主要为熔合区附近的细晶层组织和尺寸差异较大的等轴晶组织，仅在靠近细晶层的局部，存在极少量的柱状晶组织。
（3）7050-T7451铝合金焊缝区显微硬度平均值仅为母材区的55.3%，热影响区显微硬度略低于母材；焊接接头（焊态）平均抗拉强度约为377 MPa，达到母材的73%；平均断后伸长率为2.0%，仅达到母材的28%，均高于激光自熔焊接接头的拉伸性能。拉伸断口呈现以脆性断裂为主的混合断裂特征。
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  • 国家重点研发计划项目(2023YFB4606200)
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2025年第53卷第12期
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doi: 10.11868/j.issn.1001-4381.2024.000056
  • 接收时间：2024-01-23
  • 首发时间：2026-10-26
  • 出版时间：2025-12-20
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  • 收稿日期：2024-01-23
  • 录用日期：2024-02-23
基金
国家重点研发计划项目(2023YFB4606200)
作者信息
    1.中国航空制造技术研究院，北京 100024
    2.航空工业庆安集团有限公司，西安 710077

通讯作者:

许飞（1982—），男，高级工程师，硕士，研究方向为轻质合金激光及激光电弧复合焊接，联系地址：北京市朝阳区朝阳路1号中国航空制造技术研究院（100024），E-mail：
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
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红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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